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Quality
TQM- Definition
TQM- Model
Design Quality Tools- FMEA and QFD
Process Quality Tool- FMEA
Taguchi Loss Function- Minitab Introduction
Product quality vs service quality parameters
Reactive Approach
Operational techniques to make
Quality inspection more efficient & to
Control reduce the costs of quality.
Detection 2
(example: SPC)
Finding & Fixing
mistakes
Inspection Inspect products
1
T. Q. M.
Continuous Improvement
(through measurement and analysis)
Technical
requirements
Voice of Relationships
the between Priorities Competit
custom customer of ive
er and technical customer evaluatio
requirements requirem n
ents
Priorities of
technical
9/19/17 requirements
TIM-19-Dr. Sachin -SIOM Nashik
FMEA-History
An offshoot of Military Procedure MIL-P-1629, titled Procedures for
Performing a Failure Mode, Effects and Criticality Analysis, dated November
9, 1949.
Used as a reliability evaluation technique to determine the effect of system
and equipment failures.
Failures were classified according to their impact on mission success and
personnel/equipment safety.
Formally developed and applied by NASA in the 1960s to improve and
verify reliability of space program hardware.
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Class.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Function
Mode Failure of Failure Control Target
Date
13. Classification :
Classify any special product characteristics (e.g.critical, key major,
significant) for components, subsystem, system that may require
additional process controls. Each item identified here in Design FMEA
should have the special process controls identified in the Process
FMEA.
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
1 in 8 8 >1.33
High : Repeated failures
1 in 20 7 >1.17
1 in 80 6 >1.00
Moderate : Occasional
failure 1 in 400 5 >0.83
1 in 2,000 4 >0.67
Low : Relatively few
failures 1 in 15,000 3 >0.51
1 in 150,000 2 >0.33
Remote : Failure is
unlikely < 1 in 1,500,000 1 < 0.33
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
17. Detection : It is an
assessment of the ability of the proposed type (2) current design control, to
detect a potential cause or the ability of the proposed type (3) current design
controls to detect the subsequent failure mode before the component, system,
subsystem is released for production.
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Occurrence
Occurrence
Detection
Potential Potential Potential Current Recom. Responsi Action
Detection
Item /
Severity
Severity
R.P.N.
Failure Effect of Causes Design Action bility & Taken
R.P.N.
Class
Function
Mode Failure of Failure Control Target
Date
Design FMEA
Failure Mode Effect Cause
Process FMEA
Failure Mode Effect Cause
Necessit Problem Effects How bad Causes How Likely? Score Steps to
y is it? Prevent
Failure Occurrence
Process Mode Severity
Function
Put PB on
bread
Necessit Problem Effects How bad Causes How Likely? Score Steps to
y is it? Prevent
Failure Occurrence
Process Mode Severity
Function
Put PB on No PB Jelly
bread Sandwich
Taguchis Traditional
When a product There is Good or Bad
moves from its Products only as per
Target will cause the Limits
loss even if the
product lies or not
within Limits
Taguchi loss Fn
Loss
Measured
characteristic
i.e. 50 = k(0.20)2
K=125,000
US plant variance
= 8.33
D2 =(x-T) 2
K=0.16
For San Diego plant, variance was 8.33
For Japanese plant, variance was 2.78
9/19/17 TIM-19-Dr. Sachin -SIOM Nashik
Loss:
San Diego = 0.16 x 8.33 = USD 1.33
Japanese = 0.16 x 2.78 = USD 0.44
Dimension Definition
Dimension Definition